Lincoln Electric CLASSIC III 10156, CLASSIC III 10061, CLASSIC III 10033, CLASSIC III 10072 User Manual
CLASSIC ®III & CLASSIC ®III D
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For Machines with Code Numbers 10033, 10061, 10072 or 10156
Safety Depends on You
Lincoln arc welding equipment
is designed and built with safety
in mind. However, your overall
safety can be increased by
proper installation ... and
thoughtful operation on your
part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
And, most importantly, think
before you act and be careful.
IM529-A
October, 1999
Supersedes IM482
OPERATOR’S MANUAL
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
i
SAFETY
i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ‘95
ii
SAFETY
ii
ELECTRIC SHOCK can
kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
5.b.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating
products.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
Mar ‘95
vapors
to
iii
SAFETY
iii
WELDING SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.
Remember that welding sparks and hot
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
iv
SAFETY
iv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.
vv
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Technical Specifications.......................................................................................................A-1
General Description..............................................................................................................A-2
Design Features ...................................................................................................................A-2
Pre-Operation Installation.....................................................................................................A-3
Safety Precautions ........................................................................................................A-3
Exhaust Spark Arrester .................................................................................................A-3
Location/Ventilation.......................................................................................................A-3
Stacking ........................................................................................................................A-3
Angle of Operation ........................................................................................................A-3
Machine Grounding.......................................................................................................A-3
Lift Bail ..........................................................................................................................A-4
Trailers ..........................................................................................................................A-4
Polarity Control and Cable Sizes ..................................................................................A-4
Pre-Operation Service..........................................................................................................A-5
Oil..................................................................................................................................A-5
Fuel ...............................................................................................................................A-5
Cooling System .............................................................................................................A-5
Battery Charging ...........................................................................................................A-5
vi
Operation.........................................................................................................................Section B
Engine Operation .................................................................................................................B-1
Starting The Continental TM27 Engine ................................................................................B-1
Starting The Continental TMD27 Engine..............................................................................B-1
Stopping the engine .............................................................................................................B-1
Welder Operation .................................................................................................................B-2
Duty Cycle ............................................................................................................................B-2
Control of Welding Current...................................................................................................B-2
Idler Operation......................................................................................................................B-2
Auxiliary Power .............................................................................................................B-3
Carburetor Deicing Kit
Accessories ....................................................................................................................Section C
Optional Features (Field Installed) .......................................................................................C-1
Maintenance....................................................................................................................Section D
Safety Precautions ...............................................................................................................D-1
General Instructions..............................................................................................................D-1
Cooling System.....................................................................................................................D-1
Bearings................................................................................................................................D-1
Commutator and Brushes .....................................................................................................D-1
Idler Maintenance .................................................................................................................D-2
Nameplates...........................................................................................................................D-2
Engine Service Chart ............................................................................................................D-3
...............................................................................................B-3
Troubleshooting .............................................................................................................Section E
Safety Precautions ...............................................................................................................E-1
Welder Troubleshooting ........................................................................................................E-2
Electronic Idler Troubleshooting Guide .................................................................................E-3
Engine Troubleshooting Guide (TM27 Only) ................................................................E-4, E-5
Diagrams..........................................................................................................................Section F
Wiring Diagram (Classic III)..................................................................................................F-1
Wiring Diagram (Classic III D) ..............................................................................................F-2
Dimension Print ....................................................................................................................F-3
Parts Manual..............................................................................P232 Series (IIID), P302 Series (III)
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS – CLASSIC III AND IIID
Machine
A-1
Product
Name
Classic III
Classic III D
Ordering
Information
K1428-2
@
CSA
w/o Wire Feed
Module
K1428-3
@
CSA
w/ Wire Feed
Module
K1433-1
@
CSA
w/o Wire Feed
Module
K1433-2
@
CSA
w/ Wire Feed
Module
@
Meets Canadian Standards
Description
300 Amp DC
Arc Welder
All Copper
Windings
Pure DC Power
Generator
Rated DC Output *
Amps / Volts / Duty Cycle
225A / 29V / 100%
300A / 32V / 50%
350A / 34V / 30%
* Based on a 10 min. period.
DC Current Range
(Fine Adjustment in Each Range)
40 - 350 Amps
220 - Max
160 - 240
120 - 190
80 - 130
Min - 90
40 - 350 Amps
220 - Max
160 - 240
120 - 190
80 - 130
Min - 90
Auxiliary
Power
3000 Watts,
60 Hz. AC
26 Amps @
115V
13 Amps @
230V
3000 Watts,
60 Hz. AC
26 Amps @
115V
13 Amps @
230V
Dimensions
& Weight
40.94 x 24.0 x 66.25in
(1040 x 610 x 1683 mm)
1406 lbs (638 kg)
40.94 x 24.0 x 66.25 in
(1040 x 610 x 1683mm)
1445 lbs (657 kg)
Engine
Product
Name
Classic III
Classic III D
Description Horsepower Operating
4 Cylinder
4 Cycle
Water-Cooled
Gasoline Engine
Cast Iron Cylinder,
Block/Crankcase
4 Cylinder
4 Cycle
Water-Cooled
Diesel Engine
Cast Iron Cylinder,
Block/Crankcase
45 HP
@ 1700 RPM
38.9 HP
@ 1700 RPM
Speeds
Full Load:
1725 RPM
High Idle:
1800 RPM
Low Idle:
1350 RPM
Displacement Ignition Capacities
Distributor Type
Electronic
164.7 Cu In
(2.7 ltrs)
Diesel
Fuel:
15 Gals (57 Ltrs)
Lubricating Oil:
7.0 Qts (6.7 Ltrs)
Coolant:
9.3 Qts (8.8 Ltrs)
CLASSIC III AND IIID
A-2
INSTALLATION
A-2
GENERAL DESCRIPTION
The Classic®III and Classic®III D are heavy duty,
engine driven, DC arc welding power sources capable
of providing constant current output for stick welding
or DC TIG welding. These welders are wound with all
copper coils, rated at 300 amps/32 Volts, and provide
other Classic features such as improved door latches
and stainless hinges. With the addition of the optional
K623-1 Wire Feed Module™, the Classic III or Classic
III D will provide constant voltage output for running
the LN-7, LN-23P, or LN-25 wire feeders. (The Wire
Feed Module is factory installed on the K1428-3 and
K1433-2).
The Classic III D has Diesel Engine Protection. In the
event of sudden low oil pressure or high coolant temperature, the engine immediately shuts down. The
Classic III & Classic III D have a current range of 40350 DC amps with output ratings as follows:
RATED OUTPUT DUTY CYCLE
225A @ 29V
300A @ 32V
350A @ 34V
These units are also capable of providing 3 kVA of
115/230 volts of 60 cycle AC auxiliary power.
100%
50%
30%
DESIGN FEATURES
Control Panel
Both the engine and the welder controls are located
on one recessed panel at the exciter end of the
machine. The welder controls consist of a five step
“Current Range Selector” switch and a “Fine Current
Adjustment” rheostat. Each welder is equipped with a
“Start” button, an “Ignition” switch and an “Idler” control switch. The diesel version comes with a “Glow
Plug” feature for easier cold weather starting.
The control panels also contain an engine temperature gauge (diesel only), a battery charging ammeter,
an oil pressure gauge (oil pressure light on the gasoline version), two three prong grounding type receptacles and circuit breakers for auxiliary power, and a
choke control (gasoline version only).
All Copper Windings - For long life and dependable
operation.
Engine Idler - Both the Classic III & III D are
equipped with an electronic automatic engine idler. It
automatically increases and decreases engine speed
when starting and stopping welding or using auxiliary power. A built-in time delay permits changing
electrodes before the engine slows to its low idle
speed. The “Idler” control switch on the panel locks
the idler in full speed position when desired.
The Classic III unit uses the Continental TM27
industrial water-cooled Gasoline engine, while the
Classic III D uses the Continental TMD27®industrial
water-cooled Diesel engine.
Auxiliary Power - 3.0 kVA of nominal 115/230V,
®
60Hz, AC. Output voltage is maintained within ± 10%
at all loads up to rated capacity. (See Optional
Features for Power Plug Kits.)
Welder Enclosure - The complete welders are rubber
mounted on a rugged steel “C” channel base.
The output terminals are placed at the side of the
machines so that they are protected by the door. The
output terminals are labeled (+) and (-).
Cranking System - A 12 volt electric starter is standard.
Air Cleaner - Heavy duty two stage dry type.
Muffler - A muffler and rain cap are standard.
Engine Hour Meter - A meter to record hours of oper-
ation.
Diesel Engine Protection - The system shuts the
diesel engine down in the event of sudden low oil
pressure or high coolant temperature.
Carburetor Deicing Kit
Classic III Welders are equipped with a kit, that
prevents carburetor icing when outside temperature is
60°F/15.5°C or lower.
CLASSIC III AND IIID
A-3
INSTALLATION
A-3
PRE-OPERATION INSTALLATION
WARNING
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
------------------------------------------------------------------------
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information at the
front of this operator’s manual.
-----------------------------------------------------------
Exhaust Spark Arrester
Some federal, state or local laws may require that
engines be equipped with exhaust spark arresters
when they are operated in certain locations where
unarrested sparks may present a fire hazard. The
standard mufflers included with these welders do not
qualify as spark arresters. When required by local
regulations, suitable spark arresters must be installed
and properly maintained.
CAUTION
Use of an incorrect arrester may lead to engine damage
or performance loss. Contact the engine manufacturer
for specific recommendations.
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Location / Ventilation
STACKING
Classic III and III D machines cannot be stacked.
ANGLE OF OPERATION
To achieve optimum engine performance the Classic
III and III D should be run in a level position. The maximum angle of operation for the TM27 and TMD27
engines is 60 degrees in a direction to cause the air
intake manifold to be angled up, 45 degrees for the air
intake manifold to be angled down, and 50 degrees
for the welder control panel to be angled up or down.
If the engine is to be operated at an angle, provisions
must be made for checking and maintaining the oil
level at the normal (FULL) oil capacity in the
crankcase. When operating the welder at an angle,
the effective fuel capacity will be less than the specified 15 gallons (57 Ltrs.).
Machine Grounding
According to the United States National Electrical
Code, the frame of this portable generator is not
required to be grounded and is permitted to serve as
the grounding means for cord connected equipment
plugged into its receptacle.
Some state, local, or other codes or unusual operating
circumstances may require the machine frame to be
grounded. It is recommended that you determine the
extent to which such requirements may apply to your
particular situation and follow them explicitly. A
machine grounding stud marked with the symbol is
provided on the welding generator frame foot. (If an
older portable welder does not have a grounding stud,
connect the ground wire to an unpainted frame screw
or bolt.) In general, if the machine is to be grounded,
it should be connected with a #8 or larger copper wire
to a solid earth ground such as a metal water pipe
going into the ground for at least ten feet and having
no insulated joints, or to the metal framework of a
building which has been effectively grounded. The
U.S. National Code lists a number of alternate means
of grounding electrical equipment.
Always operate the welder with the doors closed.
Leaving the doors open changes the designed air flow
and may cause overheating.
The welder should be located to provide an unrestricted flow of clean, cool air. Also, locate the welder so
that engine exhaust fumes are properly vented to an
outside area.
CLASSIC III AND IIID
A-4
INSTALLATION
A-4
Lift Bail
A lift bail is provided for lifting with a hoist.
WARNING
FALLING EQUIPMENT can cause
injury.
• Do not lift this machine using lift bale if
it is equipped with a heavy accessory
such as a trailer or gas cylinder.
• Lift only with equipment of adequate lifting capacity.
• Be sure machine is stable when lifting.
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Trailer (See Optional Features)
If the user adapts a non-Lincoln trailer, he must
assume responsibility that the method of attachment
and usage does not result in a safety hazard nor damage the welding equipment. Some of the factors to be
considered are as follows:
Polarity Control and Cable Sizes
With the engine off, route the electrode and work
cables through the strain relief bracket on the base
and connect to the studs located below the fuel tank
mounting rail. (See size recommendations below.)
For positive polarity, connect the electrode cable to
the terminal marked “+”. For Negative polarity, connect the electrode cable to the “-” stud. These connections should be checked periodically and tightened
if necessary.
When welding at a considerable distance from the
welder, be sure you use ample size welding cables.
RECOMMENDED COPPER CABLE SIZES
Cables Sizes for Combined Length
of Electrode Plus Work Cable
Amps Duty Cycle Up to 200 ft. 200 to 250 ft.
225 100% 1 1/0
300 50% 1/0 2/0
350 30% 2/0 3/0
1. Design capacity of trailer vs. weight of Lincoln
equipment and likely additional attachments.
2. Proper support of, and attachment to, the base of
the welding equipment so there will be no undue
stress to the framework.
3. Proper placement of the equipment on the trailer to
ensure stability side to side and front to back when
being moved and when standing by itself while being
operated or serviced.
4. Typical conditions of use, i.e., travel speed, rough-
ness of surface on which the trailer will be operated;
environmental conditions, likely maintenance.
5. Conformance with federal, state and local laws.
(1)
Consult applicable federal, state and local laws regarding specific
requirements for use on public highways.
(1)
CLASSIC III AND IIID
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